Flexible package having an automatic closure feature

ABSTRACT

A reclosable flexible package is suitable for retail sale of food products and is comprised of a film material. The reclosable flexible packages are suitable for mass production on high-speed form-fill-seal equipment. The flexible package includes a pair of semi-rigid strips attached to the walls of the flexible pouch and positioned parallel to the package opening. The semi-rigid strips are configured and arranged to nest together and bias toward one another. Upon opening of the package, the semi-rigid strips are moveable between a closed position and an open position. Further, the semi-rigid strips are configured such that they automatically reclose the package when the strips are released from the open position.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional application No.61/047,695, filed Apr. 24, 2008, which is incorporated by reference inits entirety herein. This application is a continuation-in-part of U.S.patent application Ser. No. 12/247,903, filed Oct. 8, 2008, and is aContinuation-in-Part of U.S. patent application Ser. No. 12/347,374,filed Dec. 31, 2008, both of which claim the benefit of U.S. ProvisionalApplication No. 61/047,695, and all of which are incorporated byreference in their entirety herein.

TECHNICAL FIELD

This invention relates generally to packaging, and more particularly toa disposable food packaging comprising a pouch made of a film materialwith an automatic closure feature.

BACKGROUND

Flexible film packages are well known in the art and typically comprisedisposable pouches commercially produced on high-speed form-fill-sealmachines from rolls of plastic film material. The flexible film packageshave cavities within which pluralities of contents, such as foodproducts, are stored. Consumers often consume only a portion of thepackage's contents. A package reclosability feature allows the user todischarge a portion of the contents through the package opening and thenseal the opening to reclose the flexible package.

Numerous reclosable flexible packages are well known in the art. By oneapproach, reclosable flexible packages have press-to-close zipperclosures. Press-to-close zippers require alignment of two profileslocated on opposing package walls to interlock the closure and reclosethe package. This alignment may be cumbersome and/or time consuming forconsumers, especially younger or older consumers who may have limitedmanual dexterity. In addition, if a particulate food product, likeshredded cheese or bread crumbs, is stored within the flexible package,the particulate may interfere with the alignment of the zipper profiles,which often have narrow channels or tracks.

In another approach, the reclosable flexible packages include a sliderzipper closure. The slider closures on these flexible packages assistwith the alignment of the two profiles located on the package walls;however, these slider closures require additional plastic material andmanufacturing that come with additional costs. While the sliders allowthe users to more easily align the package wall profiles, the sliderclosures create a slight opening between the slider and the side sealwhen the package is in the closed configuration. Further, the zipperslider remains on the slider tracks when the package is in the openposition and the slider extends into the opening, thereby slightlyreducing the size of the pouch opening.

In addition, typical recloseable flexible packages do not automaticallyreclose themselves. These reclosable flexible packages typically requireaffirmative manual action to reclose. Thus, the user must remember toclose the package and accurately press-to-seal the closure or pull thezipper slider to the closed configuration between each usage. Further,if one of these reclosable flexible packages is inadvertently dropped,while open, the contents may be permitted to spill out. The consumermust remember or have sufficient time to reclose the package to avoidpossible spilling or spoilage of the package contents.

SUMMARY

The package described herein comprises a flexible pouch made of filmmaterial and a pair of semi-rigid strips attached to the walls of theflexible pouch positioned such that the semi-rigid strips align and biastoward one another. Upon removal of the top portion, the semi-rigidstrips are moveable between a closed position and an open position.Further, the semi-rigid strips are configured such that theyautomatically reclose the package when the strips are released from theopen position. The strips may extend along the entire width of theflexible pouch or may extend between the side seals of the pouch.

To commercially produce the self-closing flexible package having thesemi-rigid strips, high-speed form-fill-seal equipment having a verticalor horizontal configuration may be employed. In one embodiment, cavitiesare formed out of film material in an in-line operation such that thestrips may be added to the inside or outside surfaces of the filmmaterial. The semi-rigid strips may be secured to the front and backpanels by heat sealing or adhesive bonding.

BRIEF DESCRIPTION OF THE DRAWINGS

The above needs are at least partially met through provision of theflexible pouch having an automatic closure feature described in thefollowing detailed description, particularly when studied in conjunctionwith the drawings, wherein:

FIG. 1 comprises a front elevational view of a flexible package asconfigured in accordance with various embodiments of the invention;

FIG. 2 comprises a cross sectional view of the flexible package of FIG.1 along line 2-2;

FIG. 3 comprises an isometric cross sectional view of the flexiblepackage of FIG. 1 in the open configuration;

FIG. 4 comprises a cross sectional view of the flexible package of FIG.1 in the open configuration;

FIG. 5 comprises a perspective view of the flexible package of FIG. 1 inthe open configuration;

FIG. 6 comprises a front elevational view of another embodiment of aflexible package;

FIG. 7 comprises a cross sectional view of the flexible package of FIG.6 along line 7-7;

FIG. 8 comprises a rear elevational view of another embodiment of aflexible package;

FIG. 9 comprises a cross sectional view of the flexible package of FIG.8 along line 9-9;

FIG. 10 comprises a cross sectional view of another embodiment of aflexible package;

FIG. 11 comprises a perspective view of the flexible package of FIG. 10in the open configuration;

FIG. 12 comprises a partial perspective view illustrating an apparatusas configured in accordance with an embodiment of the invention;

FIG. 13A comprises a partial perspective view illustrating an apparatusconfigured in accordance with an embodiment of the invention;

FIG. 13B comprises a partial perspective view illustrating an apparatusas configured in accordance with an embodiment of the invention;

FIG. 14 comprises a partial perspective view illustrating an apparatusas configured in accordance with an embodiment of the invention;

FIG. 15 comprises a perspective view of a of another embodiment of aflexible package;

FIG. 16 comprises a cross sectional view of the flexible package of FIG.15;

FIG. 17 comprises a perspective view of the flexible package of FIG. 15in the open configuration;

FIG. 18 comprises a perspective view of another embodiment of a flexiblepackage;

FIG. 19 comprises a cross sectional view of the flexible package of FIG.18; and

FIG. 20 comprises a partial perspective view illustrating an apparatusas configured in accordance with an embodiment of the invention.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions and/or relative positioningof some of the elements in the figures may be exaggerated relative toother elements to help to improve understanding of various embodimentsof the present invention. Also, common but well-understood elements thatare useful or necessary in a commercially feasible embodiment are oftennot depicted in order to facilitate a less obstructed view of thesevarious embodiments of the present invention. It will further beappreciated that certain actions and/or steps may be described ordepicted in a particular order of occurrence while those skilled in theart will understand that such specificity with respect to sequence isnot actually required. It will also be understood that the terms andexpressions used herein have the ordinary technical meaning as isaccorded to such terms and expressions by persons skilled in thetechnical field as set forth above except where different specificmeanings have otherwise been set forth herein.

DETAILED DESCRIPTION

Generally speaking, pursuant to these various embodiments, a flexiblepackage or pouch with an automatic closure feature is illustrated inFIGS. 1-11. The flexible pouch 10, as shown in FIGS. 1-5, may be usedfor packaging food products 12, such as particulate food productsincluding shredded cheese, cereal, and trail mix, to note but a few. Theflexible pouch 10 has a pair of curved semi-rigid strips 14, 16 that runparallel to the pouch opening. The curved, semi-rigid strips 14, 16 areconfigured and arranged to nest together and bias toward one another.The first and second semi-rigid strips 14, 16 are secured to the opposedfront and back panels 18, 20 of the flexible pouch 10 and the biasing ofthe strips 14, 16 biases the panels 18, 20 to the closed configuration.The flexible pouch 10 may be comprised of a flexible film material thatis formed using high-speed form-fill-seal equipment. The flexible pouchmay have a variety of seals, folds, and other features as determined bya variety of considerations, such as the products stored in the pouchand the method of manufacturing the pouch, to note but a few.

In one illustrative embodiment, as depicted in FIG. 1, the flexiblepouch 10 includes front and back panels 18, 20 that have a side seals22, a top seal 24, and a bottom fold 26. To facilitate access to theproduct, the flexible pouch 10 includes a removable top portion 28. Adistance below the removable top portion 28, the front and back panels18, 20 have curved semi-rigid strips 14, 16 located thereon. Uponremoval of the top portion, the curved semi-rigid strips 14, 16 aremovable between an open position permitting dispensing of the foodproduct and a closed position that limits or prevents egress of the foodproduct.

As shown in FIG. 1, the side seals 22 extend along the outside edges ofthe panels 18, 20 to create the pouch 10. The side seals 22, top seal 24and similar seals discussed herein may be conventional heat-seals. Suchconventional heat seals may be created by reciprocating heat sealingbars or other suitable sealing apparatus and are well known to thoseskilled in the art.

In addition, the flexible pouch 10 includes an area of weakness 30 thatassist the user with separating the removable top portion 28 from theflexible pouch 10. The area of weakness 30 may be a mechanical or laserscore line. This line may be linear or non-linear. If the area ofweakness is non-linear, the flange at the top of the package (discussedbelow) may not extend entirely across the package width. In addition toa laser score line, the area of weakness 30 may include perforations.The score line or perforations may be extended along the entire width ofthe flexible pouch 1O. Instead, or in addition to a score line, the areaof weakness 30 may include a tear initiation feature 32 along only aportion of the pouch, such as, for example, a small V-notch or slit onone edge of the package. For example, as shown in FIG. 1, the area ofweakness 30 may include a tear initiation feature 32 aligned with ascore line.

Where the flexible pouch 10 is used for food products 12, a hermeticseal 34 is desirable to ensure product freshness. The hermetic seal 34may have a pealably openable characteristic. In the illustrativeembodiment of FIG. 1, the pealable hermetic seal 34 is positioned belowthe curved semi-rigid strips 14, 16. In another embodiment, the hermeticseal 34 may be created by the top seal 24 if the area of weakness 30takes the form of a score line as opposed to perforations, which wouldinterfere with the hermetic seal 34 created by the top seal 24. Inaddition, the flexible pouch 10 may have a tamper evidence feature.

Below the area of weakness 30, the front and back panels 18, 20 eachhave a curved semi-rigid strip 14, 16 secured thereon. The curvedsemi-rigid strips 14, 16 have a slight arc and are positioned on thepanels 18, 20 such that the curved strips nest tightly together. Moreparticularly, the curvature of the first curved semi-rigid strip 14aligns in the same direction as the curvature of the second curvedsemi-rigid strip 16 as illustrated in FIG. 2. The radius of curvature ofthe curved semi-rigid strips 14, 16 may be larger or smaller than thatillustrated in FIG. 2.

The curved semi-rigid strips 14, 16 may have a variety of dimensions.For example, the strips 14, 16 may have a radius of curvature from 0.125to 6.0 inches, a thickness of 0.007 to 0.050 inches, a height of 0.125to 2.5 inches, and a length of 0.75 to 20 inches. In one illustrativeembodiment, the curved semi-rigid strips 14, 16 are about 1.25 inches inheight, 5.75 inches in length, with a radius of curvature of 1.25inches, and a thickness of about 0.015 inches. Depending on thedimensions and features of the flexible pouch 10, the curved semi-rigidstrips 14, 16 may extend the entire width of the package, as shown inFIG. 1, or may extend in between the side seals 22 such that the strips14, 16 terminate at the inside margin of the side seal 22. Otherembodiments are contemplated, such as, for example, an embodiment havingcurved semi-rigid strips 14, 16 that terminate in the middle of the sideseals 22.

As suggested, the curved semi-rigid strips 14, 16 bias toward oneanother to automatically close the flexible pouch 10 upon release fromthe open position. The curved semi-rigid strips 14, 16 are in theirstable resting configuration when they are extended to their fulllength. When the curved semi-rigid strips 14, 16 are separated and movedto a fully open position, as shown in FIGS. 3 and 4, lengthwise tensionis induced in the strips 14, 16 such that when the strips are releasedfrom that position, they automatically move to the fully extendedposition which brings the strips 14, 16 together tightly and closes theflexible pouch 10. Further, in addition to the curved semi-rigid strips14, 16 imparting an automatic closure feature to the flexible pouch 10,the strips 14, 16 create an audible snap when the flexible packagerecloses. The audible snap assures the consumer that the package issecurely closed and the unused portion of the contents will remainfresh.

As shown in FIG. 1, the curved semi-rigid strips 14, 16 are positionedparallel to the opening created at the top of the pouch 10 upon theremoval of the top portion 28. In addition, the curved semi-rigid strips14, 16 are positioned a distance form the area of weakness 30. In oneembodiment, the strips 14, 16 are positioned about 0.75 inches from thetop film edge. This distance may vary and a desired distance may bebetween 0.125 and 2.0 inches.

The curved semi-rigid strips 14, 16 may be comprised of a variety ofmaterials including a relatively heat resistant polymer such aspolyethylene terephthalate (PET), high impact polystyrene (HIPS),polypropylene (PP), high density polyethylene (HDPE), another of avariety of relatively stiff polymers, or a thin strip of resilient metalsuch as a thin strip of steel. The curved semi-rigid strips 14, 16 maybe secured to the panels 18, 20 in a variety of manners such as, forexample, by heat sealing or adhesive bonding. Further, the strips 14, 16may be attached to the inside or outside surfaces of the panels 18, 20.By one approach, the first and second curved semi rigid strips 14, 16have an external heat seal layer compatible with a sealant on therespective front and back panels 18, 20.

The semi-rigid spring-loaded strips 14, 16 may be produced in a varietyof manners such as by stamping, injection molding, thermoforming,extrusion, or by a combination of two or more of these processes. Forexample, the strips may be stretched and rapidly quenched after profileextrusion. In addition, the curved semi-rigid strips 14, 16 may beproduced either as separate elements, pairs, or as a continuous ribbonof strip material wound onto a reel. In one embodiment, the curvedsemi-rigid strips 14, 16 may be brought to the line in pre-cut strips.In another manufacturing process, the curved semi-rigid strips 14, 16may be formed in-line. For example, in one embodiment, the material fromwhich the curved semi-rigid strips 14, 16 is formed is wound on a reelin a flat form such that the curvature of the semi-rigid strips 14, 16is imparted by a forming process such as a thermoforming tool when thematerial is unwound from the reel.

Turning now to FIGS. 3 and 5, the flexible pouch 10 is illustrated inthe open configuration. Above the curved semi-rigid strips 14, 16 andbelow the area of weakness 30, a portion of film material extends, whichcomprises the panel flanges 36, 38. Thus, when the removable portion 28has been separated from the flexible pouch 10, the panel flanges 36, 38extend above the curved semi-rigid strips 14, 16 and may be grasped bythe user. In one illustrative embodiment, the strips 14, 16 arepositioned between 0.5 and 1.0 inches from the top edge of the filmmaterial. Thus, in one illustrative embodiment, the panel flanges 36, 38may be between 0.25 and 0.8 inches in height. Such panel flanges 36, 38provide loose film for easy grasping, which assists with the opening ofthe pouch 10.

To open the flexible pouch 10, the user may manually grasp and pull thefront and back panel flanges 36, 38 apart from one another. Pulling thepanel flanges 36, 38 with a mild force causes the package to move to afully open configuration. Once opened, the flexible pouch 10 may be heldin the fully open configuration by applying longitudinal compression tothe sides of the flexible pouch 10 where the curved semi-rigid strips14, 16 terminate. Continuous application of such longitudinalcompression retains the flexible pouch 10 in the fully openconfiguration, as shown in FIGS. 3 -5. The fully open configurationallows significant access to the food products stored within theflexible pouch 10. In one embodiment the flexible package is sized toallow one-hand manual application of the longitudinal compression.

Upon release of the longitudinal compression, the spring-tension of thecurved semi-rigid strips 14, 16 causes them to snap back to the closedposition thereby automatically closing pouch 10. As mentioned, theclosing action may be rapid and accompanied by an audible snap sound.After returning to the closed position, the matching curvature of thecurved semi-rigid strips 14, 16 is forced tightly together creating asecure closure at the top of the flexible pouch 10.

Turning now to FIGS. 6 and 7, there is illustrate another embodiment ofa flexible pouch. In this and subsequent embodiments, similar flexiblepouches are illustrated having slightly different features. Forconvenience, features of the various embodiments that correspond tofeatures already discussed with respect to previously discussedembodiments are identified using the same reference numeral incombination with a prefix (such as ‘1’) to distinguish the differentembodiment. For example, flexible pouch 110 corresponds to previouslydescribed flexible pouch 10.

As shown in FIG. 6, flexible pouch 110 includes side seals 122, a topseal 124 and a bottom seal 142. This embodiment may be produced out oftwo rolls of film material that are heat sealed together. In thisexample, the curved semi-rigid strips 114, 116 extend to the outsideedges of the side seals 122. As shown in FIG. 7, the flexible pouch 100comprises a front panel 120 that is generally vertical and a back panel118 within which a bulge is created to accommodate a plurality of foodproduct 112.

Turning now to FIGS. 8 and 9, there is illustrated another embodiment ofa flexible pouch 210. The flexible pouch 210 includes a bottom seal 242,side folds 244, and a lap or fin seal 246 along the back of the flexiblepouch 210. The fin seal 246, like side seals 22, may be conventionalheat seals. As shown in the illustrative embodiment of FIG. 9, thecurved semi-rigid strips 214, 216 are secured to the outside surfaces ofthe front and back panels 218, 220.

In yet another illustrative embodiment, depicted in FIGS. 10 and 11, aflexible pouch 310 is illustrated. The flexible pouch 310 is similar tothe flexible pouch 10 described above except that flexible pouch 310 hasonly one curved semi-rigid strip 314 secured to one of either the frontor back panels 318, 320. Such an embodiment functions similarly to thepreviously discussed embodiments, except that the closure may not be asair-tight as the previous embodiments but the flexible pouch 310 usesless strip material and thus has a cost savings.

As mentioned above, the method of manufacturing the flexible pouches mayaffect the particular seals, folds, and various other features ofparticular flexible pouches. A variety of manufacturing methods areavailable to commercially produce the flexible pouches and a fewexamples will be discussed herein and illustrated in FIGS. 12-14. Theflexible pouches may be made in a high-speed form-fill-seal (FFS)operation that produces up to 800 packages per minute. The FFS operationmay be on a vertical FFS machines as illustrated in FIG. 12 or also maybe on a horizontal FFS machine as illustrated in FIGS. 13A and 13B or ona horizontal thermoform-fill-seal (HTFFS) machine as shown in FIG. 14.The curved semi-rigid strips may also be secured to the pouches in avariety manners, such as by heat sealing or adhesive bonding via anadd-on equipment module designed to work in harmony with thepouch-making machines of the FFS operation.

In one illustrative embodiment shown in FIG. 12, the flexible pouchesare made in a vertical FFS or bagging line. A series of flexible pouchesis formed from a roll of film 48, such that the front and back panels ofthe film material define a cavity. By one approach, a web of the rolledfilm material is fed over a folding shoulder 50 such as a forming collarand mandrel to provide it with a tubular shape. Opposite longitudinaledges of the film are brought together around the fill tube 49. Thelongitudinal edges are sealed, such as by a seal tool 52 to form a finseal, or overlapped to form a lap seal. In one illustrative embodiment,the curved semi-rigid strips are wound on reels 54. The strips arebrought into alignment with a reciprocating seal tool 56 for attachmentto the walls of the flexible pouch. A bottom seal for the pouch is alsoformed by the reciprocating sealing tool 56, which may include a pair ofreciprocating sealing bars. The reciprocating sealing bars are heatsealing bars maintained at a desired temperature to apply heat andpressure to the front and rear walls. Further, the heat seal bars arebrought together on opposite sides of the tubular web so that heat isconductively transferred to the film from both sides while pressure isapplied. The sealing bars may be used in an intermittent or continuousoperation. In an intermittent operation, the film is stopped while thesealing bars engage the film. In a continuous operation, the sealingbars may move vertically at the machine speed as they engage the film.During operation, sealing tool 56 attaches the curved semi-rigid stripsand creates a top seal in a lower pouch and creates a bottom seal in anupper pouch at roughly the same time. In addition, sealing tool 56 maycontain a reciprocating knife which acts to separate the bottom pouchfrom the upper pouch. Once the operation is complete and the upper pouchhas been filled with food product, the upper pouch advances downward andbecomes the bottom pouch to which curved semi-rigid strips are attached.In addition to attaching the strips and sealing the pouches, the sealingtool 56 may also be used to impart the curvature to the curvedsemi-rigid strips and/or to create the area of weakness. By oneapproach, the sealing tool 56 has a cutting device associated therewithto create a perforation across the top of the package or a notch at theedge of the package to aid in tear initiation. By another approach, thearea of weakness in the pouch is not perforated at the package line butis pre-scored (mechanically or with a laser) at the film manufacturer.

As mentioned, the strips are attached to flexible pouches such that thecurvature of the first curved semi-rigid strip aligns with the curvatureof the second curved semi-rigid strip. The strips may be attached to thevertical FFS pouch in a variety of manners, e.g., hot melt adhesive,pressure sensitive adhesive, and heat sealing, to note but a fewoptions. As mentioned above, the curved semi-rigid strips may be appliedto the outside surfaces of the walls. In one vertical FFS process, thecurved semi-rigid strips have an external heal seal layer compatiblewith a sealant on the outside surface of the package walls. In one suchvertical FFS operation, the curved semi-rigid strips are secured to thefront and back panels in a direction perpendicular to the machinedirection on the outside surface of the panels.

After a bottom seal is formed in the flexible pouch, the partiallyformed flexible pouch is then filled with food product, which isintroduced into the pouch via the fill tube 49. In one embodiment, anarea of weakness is formed in the flexible pouches to define a removabletop portion. By one approach, a notch, score line, or other feature tofacilitate removal of the top portion of the package may then be formednear the top of the pouch. A hermetic seal may also be created in thedisposable pouch. The sealing tool 56 may perform a variety of functionssimultaneously, including: creating the bottom seal of the pouch that isabout to be filled with product; attaching the semi-rigid strips to theupper portion of the front and back panels and creating a peelable heatseal just below the strips on the pouch that was just filled; and havinga reciprocating knife or cutting tool which separates the pouch that wasjust filled from the following one which is about to be filled. Thereciprocating cutting tool may also create an area of weakness such as aperforation across the top of the package or a notch at the packageedge. By another approach, the area of weakness in the pouch is notperforated at the package line but is pre-scored (mechanically or with alaser) at the film manufacturer such that the scored area of weakness isbuilt into the film as it arrives from the manufacturer. If such anapproach is taken, the film should be positioned on the packagingmachine via optical registration so that the previously imparted scoreline is in the correct position when the flexible pouch is formed.

There are a variety of alternative steps to those described in thisvertical FFS operation. Also, high speed techniques may be employedinstead of application of heat and pressure by heat seal bars asdescribed above. For example, RF energy, ultrasonic energy or othertechniques may be employed.

In another example, shown in FIG. 13A, flexible pouches are manufacturedin a horizontal FFS or a flow-form wrapper. Like the vertical processdescribed above, a series of flexible pouches is formed and the filmmaterial defines a cavity having front and back panels. FIG. 13Aillustrates a single roll of film 148 being folded at a foldingapparatus 150 and then sealed with a sealing die 152 to form pouchcavities in series with one another. After the film is formed intocavities, the cavities are filled with food product. The strip-alignmentroller 158 is set at an angle to cause the strips to turn afterunwinding and to be redirected so that they are aligned in the properorientation for attachment to the flexible pouches. As shown in FIG.13A, a double roll of strips 154 a is located on the reel. As the stripsare positioned and sealed to the pouches and the pouches are advanced inthe machine direction, the strips are continuously unwound from the roll154 a and advanced in the machine direction along with the pouches. Asthe double layer of continuous strips 154 a is unwound, the strips aredispensed from the roll and positioned between the two front and backpanels of the film material. In this embodiment, the strips are sealedto the inside surface of the front and back panels. As shown in FIG.13A, the seal bars 156 seal the flexible pouch and strips from bothsides of the pouch. By one approach, having the strips on the inside ofthe pouch material makes the sealing process easier because the sealingbars 156 are configured to transfer heat through the pouch material,which is thinner than the semi-rigid strips. Whereas, the strips may beof a thicker material and thus, may require more, heat, pressure, ortime, to be affected by the heat seal process. The sealing bars 156 mayalso create an area of weakness in the package such as by a cuttingdevice associated therewith. By another approach, a separate mechanicalor laser score tool (not shown) may be employed in-line to create thescore line in the formed packages. By yet another approach, the area ofweakness such as the score line is already formed in the film when thefilm arrives from the manufacturer.

In another embodiment such as that shown in FIG. 13B, the flexiblepouches are made in a horizontal FFS or a flow-wrapper line similar tothe example shown in FIG. 13A. A series of flexible pouches is formedfrom a single roll of film 148 that is folded at a folding apparatus150, such as a folding plow as shown in FIG. 13B, and then sealed with asealing die 152 to form pouch cavities in series with one another. Afterthe film is formed into cavities, the cavities are filled with foodproduct. In the illustrative embodiment of FIG. 13B, the horizontal FFSprocess has two separate reels 154 b with curved semi-rigid strips,instead of the single roll of double layer strips 154 a shown in FIG.13A. A continuous ribbon of curved semi-rigid material is dispensed tothe line from the reel and then secured to the pouch cavities at sealingdie 156. It is also contemplated that pre-cut strips may be broughtin-line and secured to the flexible film pouches. The sealing die 156also imparts a top seal to the flexible pouch and may also create apeelable seal, if desired. The filled cavities are then separated fromone another, such as by a reciprocating knife, not shown.

In yet another embodiment, illustrated in FIG. 14, the flexible pouchesare made on horizontal thermoform-fill-seal equipment (TFFS). As shown,such a process may employ two rolls of film material 248 a, 248 b. Aseries of product cavities are thermoformed from a flexible plasticbottom film 248 b, which can then be filled with a food product. Theforming of the bottom film 248 b occurs at thermoforming station 260.After the lower cavities are filled with a product, the curvedsemi-rigid strips are introduced at the proper position between the topand bottom films. The strips may arrive to the in-line process pre-cutor on a continuous reel of semi-rigid spring strip material that may ormay not require further forming processing. In the illustrativeembodiment of FIG. 14, the curved semi-rigid strips are positioned ontwo reels 254, mated together with one another at strip roller guide258, and brought in series to be attached to the flexible pouch.

After alignment of the curved semi-rigid strips and the top and bottomfilms, the films and the semi-rigid strips enter a sealing station 256.This sealing station 256 is generally contained within a vacuum chamber,especially when the food product requires low oxygen vacuum packaging ormodified atmosphere packaging. Within the sealing station 256 are anupper moveable heated seal bar 257 a and an unheated moveable lower sealsupport die 257 b, which act together to apply heat and pressure to theupper and/or lower films, accomplishing all of the necessary heat sealsto define the final package (such as the package shown in FIGS. 6 and 7)including the side seals, the top and bottom seals, the peelable sealbelow the semi-rigid strips, as well as sealing the curved semi-rigidstrips to the top and bottom films.

Upon leaving the sealing station 256, the formed flexible pouches movein series to a trim station 262 where the pouches are separated from oneanother. The trim station 262 may also create the area of weakness inthe pouches such as by a cutting device. Alternatively, a separatemechanical or laser score tool (not shown) may be employed in-line tocreate the score line in the film as it is unwound from the roll, priorto forming the packages. By another approach, the area of weakness isalready formed in the film when the film arrives from the manufacturer.However, if pre-scored film is employed it should be registered on thepackaging machine so that the scored line is in the correct positiononce the pouches have been formed.

By one horizontal TFFS process, the strips are sealed between the topfilm 248 a and the bottom film 248 b such that they are attached to theinside surfaces of the bottom film and the top film. More particularly,the film may have a heat sealable layer on the inside surface whichseals to the resin material of the semi-rigid strips. In yet anotherembodiment, the strips have an external heat seal layer compatible witha sealant on the inside surface of the film.

The film material or substrate of the flexible pouch may be formed as apolymeric sheet of various plastic polymers, copolymers, co-extrusionsand/or laminations. Further, the film material may be a monolayerpolymeric film or a multilayer laminate comprising an outer layer ofdurable material and one or more inner barrier layers and sealantlayers. The multilayer combination may be comprised of polyolefin suchas polyethylene (high, medium, low, linear low, and/or ultra low densitypolymers including metallocene), polypropylene (non-oriented, oriented,and/or biaxially oriented); polybutylene; ethylene vinyl acetate (EVA);polyamides (non-oriented, oriented, and/or biaxially oriented) such asnylon; polyethylene terephthalate (non-oriented, oriented, and/orbiaxially oriented); polyvinyl chloride; ethylene vinyl alcohol (EVOH);polyvinylidene chloride (PVDC); polyvinyl alcohol (PVOH); polystyrene;or combinations thereof. In addition, adhesive tie layers may also beused.

In addition to the curved, semi-rigid strips 14, 16 described above, itis also contemplated that the semi-rigid strips may have alternativecross-sectional configurations. For example, an illustrative embodimentin FIG. 15 includes a flexible package 400 having a pair of semi-rigidstrips 414, 416 with a slight fold therein such that the strips have acrease, angle, or v-shape imparted thereto. The partially foldedsemi-rigid strips 414, 416 extend nearly the entire width of the packageand are parallel to the pouch opening. The partially folded, semi-rigidstrips 414, 416, like previous strips, have matching profiles and areconfigured to automatically close the package 400 once the partiallyfolded, semi-rigid strips 414, 416 are released from an open position.More particularly, once released from the open position, the strips andassociated panels 418, 420 are forced tightly together creating a secureclosure at the top of the flexible pouch 400.

As with curved, semi-rigid strips 14, 16, the partially-foldedsemi-rigid strips 414, 416 are configured and arranged to nest togetherand bias toward one another. The first and second partially-folded,semi-rigid strips 414, 416 are secured to the opposed front and backpanels 418, 420 of the flexible pouch 400 such that the profiles of thestrips align in the same direction. Further, the biasing of the strips414, 416 biases the panels 418, 420 to the closed configuration. Thepouch 400 may be comprised of a thin, flexible film material such asthat formed using high-speed form-fill-seal equipment previouslydiscussed. While the package 400 includes a side seal 422, a top seal424, and a bottom seal 426, a variety of seals, folds, and other pouchfeatures are contemplated for use with the partially-folded, semi-rigidstrips 414, 416.

The pouch 400, illustrated in FIG. 15, includes an area of weakness 430that facilitates removal of the top portion 428. The area of weakness430, by one approach, is positioned a distance below the top seal 424and a distance above the partially-folded, semi-rigid strips 414, 416such that a portion of the front and back panels 418, 420 comprises aflange 436, 438 that can be manually grasped and separated to open thepackage 400 once the top portion 428 has been removed. While flexiblepouch 400 illustrates the partially-folded, semi-rigid strips 414, 416attached to inside surfaces of the front and back panels 418, 420, asshown in FIG. 16, it is also contemplated that the strips 414, 416 maybe affixed to outside surfaces. To ensure freshness of the food product412, the flexible pouch 10 may include a hermetic seal. By one approach,the hermetic seal may include the top seal 424. By another approach, thehermetic seal may include a pealable hermetic seal 434.

Another illustrative flexible pouch 500, shown in FIGS. 18 and 19,includes planar semi-rigid strips 514, 516. By one approach, the planarsemi-rigid strips 514, 516 extend nearly the entire width of the packageand are parallel to the pouch opening. As with previous strips, planarsemi-rigid strips 514, 516 bias toward one another such that the pouchautomatically closes when the strips 514, 516 and associated panels 518,520 are forced tightly together. The planar semi-rigid strips 514, 516have a flat profile and are secured to the front and back panels 518,520 such that the strips 514, 516 generally overlap. Thus, like previousstrips, planar strips 514, 516 nest together by overlapping or havingsignificant surface to surface contact. Additional configurations forthe semi-rigid strips are contemplated. Further, the flexible pouch mayhave a variety of configurations with differing seals, folds, andvarious other features.

In addition to the variety of manufacturing methods discussed above, anumber of alterations to the various methods disclosed are contemplatedwithout changing the overall operation of the manufacturing method orthe flexible packages produced. As mentioned, high-speed form-fill-seal(FFS) operations may produce significant quantities of flexible packagesin a relatively short period of time. The various processes describedabove including the vertical manufacturing process of FIG. 12, thehorizontal manufacturing processes of FIGS. 13A-14, and the stripattachment methods discussed herein may be modified or combined forparticular manufacturing requirements or limitations. For example, apackaging system, shown in FIG. 20, employs a vertical FFS or baggingline similar to that in FIG. 12 albeit with several modifications suchthat flexible packages are produced having a top seal and two side sealsas shown produced in FIG. 13A and 13B. Further, the system of FIG. 20aligns the semi-rigid strips in a direction parallel to machinedirection or the movement of the series of pouches.

As shown in FIG. 20, flexible pouches are formed from a roll of film648, such that the front and back panels of the film material define acavity. By one approach, a web of rolled film material is fed over afolding shoulder 650 to provide the film with a tubular shape. Oppositelongitudinal edges of the film 648 are brought together around the filltube 649. The longitudinal edges are sealed, such as by seal andattachment tool 652. By one approach, the seal and attachment tool 652forms a top seal that will span the width of the package opening inbetween side seals once the flexible package is formed. In addition, theseal and attachment tool 652 may also attach semi-rigid strips to thefilm 648.

In one illustrative embodiment, the semi-rigid strips are wound on reels654 and brought into alignment with the film at the seal and attachmenttool 652 to be secured to the film. Attachment to the film may beaccomplished by a variety of mechanisms. By one approach, heat sealingmay be employed to secure the semi-rigid strips to the film. By anotherapproach, an adhesive may be used, such as a hot melt adhesive or apressure sensitive adhesive. The semi-rigid strips may have an externalheat seal layer compatible with a sealant on the outside surface of thefilm comprising the package walls. While the material wound on the reels654 may have a curvature or profile formed therein, by another approach,the profile or curvature of the semi-rigid strip may be created at theseal and attachment tool 652. In the example of FIG. 20, the semi-rigidstrips, being wound on reels 654, are secured to the film as the seriesof semi-rigid strips from the reels 654 advances in a direction parallelto the machine direction.

The seal and attachment tool 652 may also create an area of weakness ora tear initiation feature such as a notch. Alternatively, the area ofweakness may be pre-scored in the film by the film manufacturer. In sucha case, the film 648 may need to be loaded into the packaging system toensure proper placement of the area of weakness in the flexible pouch.In addition to the tool 652, the tear initiation feature may be createdduring other operations as discussed below.

As shown in FIG. 20, side seals 622 a, 622 b of the flexible package 610may be formed by a reciprocating seal tool 656, which may include a pairof reciprocating sealing bars. By one approach, the reciprocatingsealing bars are heat sealing bars maintained at a desired temperatureto apply heat and pressure to the tubular web to create the flexiblepackages. In addition, the heat seal bars 656 illustrated in FIG. 20 arebrought together on opposite sides of the tubular web so that heat isconductively transferred to the film from both sides while pressure isapplied. The sealing bars may be used in an intermittent or continuousoperation. In an intermittent operation, the film is stopped while thesealing bars engage the film. In a continuous operation, the sealingbars may move vertically at the machine speed as they engage the film.During operation, sealing tool 656 seals the side seal 622 b of a lowerpouch and creates another side seal 622 a for another, upper pouch, atsubstantially the same time. Thus, as a lower flexible pouch is sealedat a second side seal 622 b, thereby enclosing the food within theflexible package, an upper flexible pouch has a first side seal 622 acreated therein. After forming a side seal 622 a into the upper flexiblepouch, the upper flexible pouch may be filled with food and lowered toform the second side seal sealed 622 b therein. In addition to formingside seals, sealing tool 656 may create a tear initiation feature ortool 656 may contain a reciprocating knife that is configured toseparate the bottom or lowered pouch from the upper pouch.

As mentioned, after the first side seal 622 a has been created in theflexible pouch, the pouch may then be filled with product, which isintroduced via the fill tube 649. Either before or after the flexiblepouch 610 has been filled with food, the pouch may advance downward tobecome the lower or bottom pouch, then, the second side seal 622 b iscreated in the package thereby enclosing the food product in theflexible pouch 610.

The sealing tools 652 and 656, similar to sealing tools previouslydiscussed, perform a variety of functions simultaneously or in quicksuccession. For example, sealing and attachment tool 652 can create atop seal of the pouch and attach the semi-rigid strips. In addition,tool 652 may also create a peelable heat seal just below the semi-rigidstrips and may impart the curvature or formed profile of the semi-rigidstrips. By one approach, seal tool 656 creates side seals on twodifferent packages simultaneously and may also separate these packages.In addition, seal tool 656 may also include a cutting device to create anotch at the edge of the package to aid in tear initiation or may createan area of weakness in the film. The cutting device may also be used toseparate the packages as mentioned via reciprocating knife.

Those skilled in the art will recognize that a wide variety ofmodifications, alterations, and combinations can be made with respect tothe above described embodiments without departing from the spirit andscope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the ambit of the inventiveconcept.

1. A method of mass producing a packaged food product in high-speedform-fill-seal equipment comprising: forming a series of disposablepouches having front and back panels made of film material, each of thedisposable pouches defining a cavity therein; filling the cavity of thedisposable pouches with a food product; hermetically sealing thedisposable pouches; attaching a first semi-rigid strip to the frontpanel and a second semi-rigid strip to the back panel with each of thesemi-rigid strips having a profile aligned with the profile of theadjacent semi-rigid strip such that the strips align, the first andsecond semi-rigid strips being biased toward one another; and separatingthe disposable pouches from one another.
 2. The method of claim 1further comprising forming a removable top portion in the disposablepouches defined by an area of weakness.
 3. The method of claim 1 whereinthe first and second semi-rigid strips are attached to inside surfacesof the front and the back panels.
 4. The method of claim 1 wherein thefirst and second semi-rigid strips are attached to outside surfaces ofthe front and back panels.
 5. The method of claim 1 wherein the firstand second semi-rigid strips are pre-cut.
 6. The method of claim 1wherein strip material from which the first and second semi-rigid stripsare produced dispensed from a reel.
 7. The method of claim 6 wherein thestrip material is wound on the reel in flat form such that the profileof the first and second semi-rigid strips is imparted by a thermalforming tool when the material is unwound from the reel.
 8. The methodof claim 1 wherein attaching the first and second semi-rigid stripscomprises at least one of: heat sealing the first and second semi-rigidstrips to the inside surface of the front and back panels; heat sealingthe first and second semi-rigid strips to the outside surface of thefront and back panels; adhesive bonding the first and second semi-rigidstrips to the inside surface of the front and back panels; adhesivebonding the first and second semi-rigid strips to the outside surface ofthe front and back panels.
 9. The method of claim 1 wherein heat sealingthe first and second semi-rigid strips comprises having an external heatseal layer compatible on the first and second semi-rigid strips that iscompatible with a sealant on the front and back panels.
 10. The methodof claim 1 wherein the first and second semi-rigid strips are attachedin an orientation parallel to the machine direction.
 11. The method ofclaim 1 wherein the first and second semi-rigid strips are attached inan orientation perpendicular to the machine direction via a stripapplicator module configured and arranged to cut and heat-seal the firstand second semi-rigid strips to the disposable pouch.
 12. A method formass producing a packaged food product in a horizontalthermoform-fill-seal equipment comprising: thermoforming a seriesproduct cavities from a thermoformable flexible plastic bottom film;filling the thermoformed series of product cavities; securing the firstsemi-rigid strip to the bottom film; securing the second semi-rigidstrip to a flexible top film; heat sealing the flexible top film to thebottom film, the films defining a pouch wherein the first and secondsemi-rigid strips significantly overlap one another and the first andsecond semi-rigid strips have profiles that align in the same directionsuch that the strips nest together in a closed position.
 13. The methodof claim 12 wherein securing the first semi-rigid strip to the bottomfilm comprises heat sealing.
 14. The method of claim 12 wherein securingthe first semi-rigid strip to the bottom film comprises adhesivebonding.
 15. The method of claim 12 wherein the first and secondsemi-rigid strips are attached to inside surfaces of the front and theback panels.
 16. The method of claim 12 wherein the first and secondsemi-rigid strips are attached to outside surfaces of the front and theback panels.
 17. The method of claim 12 wherein the first and secondsemi-rigid strips are pre-cut.
 18. The method of claim 12 wherein stripmaterial from which the first and second semi-rigid strips are dispensedfrom wound on a reel.
 19. The method of claim 18 wherein the stripmaterial is wound on the reel in flat form such that the profile of thefirst and second semi-rigid strips is imparted by a thermal forming toolwhen the material is unwound from the reel.
 20. The method of claim 12wherein the first and second semi-rigid strips are attached in anorientation parallel to the machine direction.
 21. The method of claim12 wherein the first and second semi-rigid strips are attached in anorientation perpendicular to the machine direction via a stripapplicator module configured and arranged to cut and heat-seal the firstand second semi-rigid strips to the disposable pouch.
 22. A method formass producing a packaged food product in a vertical form-fill-sealequipment comprising: forming a flexible plastic tube from a roll offlexible plastic film, the plastic tube having a sealed edge and havinga pair of semi-rigid strips secured to the flexible film wherein thepair of semi-rigid strips significantly overlap one another once thesemi-rigid strips are secured to the flexible film; forming a first sideseal in the plastic tube to create a flexible pouch from the flexibleplastic tube; filling the flexible pouch with a food product; forming asecond side seal in the flexible pouch to seal the food product withinthe flexible pouch; and separating a filled flexible pouch from theplastic tube.
 23. The method of claim 22 wherein the semi-rigid stripshave formed profiles that align in the same direction such that thesemi-rigid strips nest together when the flexible pouch is in a closedposition.
 24. The method of claim 22 wherein forming a flexible plastictube from a roll of flexible plastic film further includes forming theflexible film over a forming collar to create the plastic tube.
 25. Themethod of claim 22 wherein the plastic tube having a sealed edge andsecuring a pair of semi-rigid strips to the flexible film includesforming a top seal in the flexible film having a front and a backpanels, the front and back panels each having one of the pair ofsemi-rigid strips attached thereto.